Kyocera FS-9120DN Service Manual
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Kyocera FS-9120DN Service Manual

Kyocera FS-9120DN Service Manual

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FS-9120DN
FS-9520DN
SERVICE
MANUAL
Published in Dec. '03
842FH110
2FH70760

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Summary of Contents for Kyocera FS-9120DN

  • Page 1: Service Manual

    FS-9120DN FS-9520DN SERVICE MANUAL Published in Dec. ’03 842FH110 2FH70760...
  • Page 2 Revision history Version Date Replaced pages Remarks Dec.-2003...

  • Page 3: Safety Precautions

    Safety precautions This booklet provides safety warnings and precautions for our service personnel to ensure the safety of their customers, their machines as well as themselves during maintenance activities. Service personnel are advised to read this booklet carefully to familiarize themselves with the warnings and precautions described here before engaging in maintenance activities.
  • Page 4 Safety warnings and precautions Various symbols are used to protect our service personnel and customers from physical danger and to prevent damage to their property. These symbols are described below: DANGER: High risk of serious bodily injury or death may result from insufficient attention to or incorrect compliance with warning messages using this symbol.

  • Page 5: Installation Precautions

    1. Installation Precautions WARNING • Do not use a power supply with a voltage other than that specified. Avoid multiple connections to one outlet: they may cause fire or electric shock. When using an extension cable, always check that it is adequate for the rated current..................... •...

  • Page 6: Specifications 1

    2. Precautions for Maintenance WARNING • Always remove the power plug from the wall outlet before starting machine disassembly....• Always follow the procedures for maintenance described in the service manual and other related brochures............................• Under no circumstances attempt to bypass or disable safety features including safety mechanisms and protective circuits.
  • Page 7 • Do not pull on the AC power cord or connector wires on high-voltage components when removing them; always hold the plug itself....................... • Do not route the power cable where it may be stood on or trapped. If necessary, protect it with a cable cover or other appropriate item.
  • Page 8 FS-9120DN/9520DN CONTENTS 1-1 Specifications 1-1-1 Specifications ............................1-1-1 1-1-2 Parts names ............................1-1-3 (1) Printer ............................. 1-1-3 (2) Operator panel ..........................1-1-4 1-1-3 Machine cross section .......................... 1-1-5 1-1-4 Drive system ............................1-1-6 (1) Drive system 1 (drive motor and eject motor drive trains) .............. 1-1-6 (2) Drive system 2 (paper feed motor drive train) ................
  • Page 9 FS-9120DN/9520DN (14) Image is partly missing......................... 1-5-33 (15) Fusing is poor..........................1-5-34 (16) Image is out of focus........................1-5-34 (17) Image is not square........................1-5-34 1-5-4 Electrical problems ..........................1-5-35 (1) The machine does not operate when the power switch is turned on..........1-5-35 (2) The drive motor does not operate (C2000).

  • Page 10: Assembly And Disassembly

    FS-9120DN/9520DN 1-6 Assembly and Disassembly 1-6-1 Precautions for assembly and disassembly ..................1-6-1 (1) Precautions ............................. 1-6-1 1-6-2 Paper feed section ..........................1-6-2 (1) Detaching and refitting the forwarding, paper feed and separation pulleys ........1-6-2 (2) Detaching and refitting the MP separation, MP paper feed and MP forwarding pulleys ....1-6-4 (3) Detaching and refitting the left and right registration cleaner ............
  • Page 11 FS-9120DN/9520DN 2-2 Electrical Parts Layout 2-2-1 Electrical parts layout ........................... 2-2-1 (1) PWBs .............................. 2-2-1 (2) Switches and sensors ........................2-2-2 (3) Motors ............................. 2-2-4 (4) Other electrical components ......................2-2-5 2-3 Operation of the PWBs 2-3-1 Power supply unit ..........................2-3-1 2-3-2 Engine controller PWB .........................
  • Page 12 Code ROM: 4 MB (2 system DIMM PWBs in sockets) Font ROM: 4 MB (PCL6 and KPDL3) Main RAM: 32 MB, expandable up to 544 MB (FS-9120DN model) 64 MB, expandable up to 576 MB (FS-9520DN model) Option expanding RAM: 2 sockets (Maximum 288 MB, including the standard RAM)
  • Page 13 " (D) Functions ........Self-diagnostics, sleep mode (energy saving) Power source ......... 120 V AC, 60 Hz, Max. 11.3 A/11.4 A (FS-9120DN/9520DN) 220 - 240 V AC, 50/60 Hz, Max. 6.0 A/6.1 A (FS-9120DN/9520DN) Power consumption ......Maximum: 1450 W...

  • Page 14: Parts Names 1

    FS-9120DN/9520DN 1-1-2 Parts names (1) Printer Figure 1-1-1 1 Operator panel ^ Cleaning brush 2 Front cover & Power cord 3 Lower paper cassette * Power cord connector 4 Paper guide ( Option unit connector 5 Paper stopper ) Handles for transport 6 Upper paper cassette ⁄...
  • Page 15 FS-9120DN/9520DN (2) Operator panel READY DATA ATTENTION Ready - - - A4 PLAIN INTERFACE SIZE TYPE MENU ENTER CANCEL Figure 1-1-2 1 GO key 2 CANCEL key 3 ENTER key 4 MENU key 5 Arrow keys 6 Ready indicator 7 Data indicator...
  • Page 16 FS-9120DN/9520DN 1-1-3 Machine cross section Light path Paper path Figure 1-1-3 Machine cross section 1 Paper feed section 2 Main charging section 3 Laser scanner unit 4 Developing section 5 Transfer and separation section 6 Cleaning and erasing section 7 Fuser section...
  • Page 17 FS-9120DN/9520DN 1-1-4 Drive system (1) Drive system 1 (drive motor and eject motor drive trains) As viewed from machine rear Figure 1-1-4 1 Drive motor gear 9 Registration clutch gear 2 Drum gear Z76H/Z30H 0 Gear Z59H/Z44S 3 Drum gear Z70H...
  • Page 18 FS-9120DN/9520DN (2) Drive system 2 (paper feed motor drive train) As viewed from machine rear Figure 1-1-5 1 Paper feed motor gear ! Lower paper feed clutch gear 2 Gear Z76H/Z35S @ Gear Z41S/P15 3 Feed gear Z25 # Bypass drive belt...

  • Page 19: Installation Environment

    1. Temperature: 10 - 32.5 °C/50 - 90.5 °F 2. Humidity: 20 - 80 % RH 3. Power supply: 120 V AC ±10 %, 11.3 A/11.4 A (FS-9120DN/9520DN) 220 - 240 V AC 10 %, 6.0 A/6.1 A (FS-9120DN/9520DN) 4. Power source frequency: 50 Hz ±0.2 %/60 Hz ±0.2 % 5.

  • Page 20: Unpacking And Installation

    FS-9120DN/9520DN 1-3-1 Unpacking and installation (1) Installation procedure Start Unpacking. Removing the tapes. Placing the proper location. Installing the toner container. Installing the waste toner box. Connecting the printer to the computer. Connecting the power cord. Printing a status page for test.
  • Page 21 FS-9120DN/9520DN Unpacking Figure 1-3-1 Unpacking Paper size plate (4) Printer CD-ROM Toner container Installation guide Quick configuration guide (for network interface) Waste toner box Power cord (220-240 V models only) Figure 1-3-2 List of shipped components 1-3-2...
  • Page 22 FS-9120DN/9520DN Removing the tapes. 1. Remove the tape holding the front cover. Tape 2. Remove the tape holding the MP tray. 3. Remove the two tapes holding the paper cassettes. Tape Tapes Figure 1-3-3 Tape 4. Remove the tapes holding the conveying cover.
  • Page 23 FS-9120DN/9520DN Placing the proper location. 1. Place the printer in a proper location. Rear: 10 cm (3 ") Right: 70 cm (27 ") Left: 60 cm (23 ") Front: 100 cm (39 ") Figure 1-3-6 Installing the toner container. 1. Open the printer front cover all the way.
  • Page 24 FS-9120DN/9520DN 4. Thoroughly shake the toner container (in the directions of the arrows) ten times or more to loosen and mix the toner inside. Toner container Figure 1-3-9 5. Grasp the handle on the toner container and Toner container insert the toner container along the rail of the printer.
  • Page 25 FS-9120DN/9520DN Installing the waste toner box. 1. Install the waste toner box as shown in the figure. Waste toner box 2. Close the front cover. Figure 1-3-12 Connecting the printer to the computer. There are various ways of connecting the printer to the computer, such as through the parallel interface connecter, USB cable connecter, or through the network interface connecter.
  • Page 26 FS-9120DN/9520DN • Parallel interface connection 1. Plug one end of the printer cable (not included) into the parallel interface connection on the right side of the printer. 2. Close the clips on both sides to fix the connector in place.
  • Page 27 FS-9120DN/9520DN Connecting the power cord. 1. Plug the power cord into the power cord connector on the rear of the printer. (220 - 240 V models only) 2. Connect the other end of the power cord into a power outlet.

  • Page 28: Installing The Cassette Heater (Option) 1

    FS-9120DN/9520DN 1-3-2 Installing the cassette heater (option) Cassette heater installation requires the following parts: • Cassette heater (P/N 34860030): for 120 V specifications • Cassette heater (P/N 33960020): for 220 - 240 V specifications • Binding band (P/N M2107120) • Two binding screws BVM4 x 6 (P/N B1304060) •...
  • Page 29 FS-9120DN/9520DN 9. Stick the label below the power switch. 10. Refit all the removed parts. Label Figure 1-3-21 1-3-10...
  • Page 30 FS-9120DN/9520DN 1-3-3 Installing DIMMs (option) Procedure • Installing DIMM DIMM 1. Remove two screws and then remove the main controller PWB (see page 1-6-24). 2. Open the clips on both ends of the DIMM socket. 3. Insert the DIMM into the socket, so that the notches on the DIMM align with the corresponding protrusions in the socket.
  • Page 31 FS-9120DN/9520DN 1-3-4 Installing the network interface card (option) Procedure 1. Remove the two screws from the option interface slot cover. * The interface card can be mounted to either of the two interface slots. If you install a hard disk, however, mount the network interface card to the upper slot (OPT2).
  • Page 32 FS-9120DN/9520DN 1-3-5 Installing the hard disk (option) Procedure 1. Remove two screws and remove the slot cover from the lower slot (OPT1/HDD). Slot cover Figure 1-3-28 2. Insert the optional hard disk unit into the slot. Hard disk unit Figure 1-3-29 3.
  • Page 33 FS-9120DN/9520DN 1-3-6 Installing the memory card (option) Procedure 1. Turn off the printer. Note: Do not insert or remove a memory card CF card (CompactFlash) while power in on. If the memory card is removed while the printer is on, damage could result in the printer's electronics or the memory card.

  • Page 34: Service Mode

    FS-9120DN/9520DN 1-4-1 Service mode The printer is equipped with the service mode that can be accessed in the manu system. The service mode is intended for use by the service person for maintenance and service for the items explained in the following sections.
  • Page 35 FS-9120DN/9520DN Service items Description Printing a status page for service purpose >>Print Description Status Page Service information on the status page include various settings for the printer, service statistics, etc. Purpose To understand the machine environments and general settings. Method 1.
  • Page 36 FS-9120DN/9520DN Service items Description Detail of service information Service information [0104/A103] [C1] [22.00AFUB] [03/03] Total page 9690 /t/P00/S00/F00/N00/D10:DM0301.DAN /0020/0020/1061/0811/ /AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/ & /AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ /AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/AAAAAAA/ ⁄ /RS2/FF/AI.E/81/31/50 ¤ ‹ › fi fl ‡ /03030303/03030303/03030303/03000000/00000000/03030303/03030303/ ° · SPD1:0203040508090A0B0C0D0F101112131415161718191A1B1C1D1E1F202122235E ‚...
  • Page 37 Bit 0: always 0 Bit 1: 0: Overseas 1: Domestic (Japan) Bit 2: Not used Bit 3: Not used Bit 4: 0: Kyocera 1: OEM Bit 5: 0: For Europe 1: For U.S. Bit 6: 0 Non MICR mode 1: MICR mode...
  • Page 38 FS-9120DN/9520DN Service items Description Item Description ⁄ Life counter of document finisher (2) Book-let tray (large) (for DF-75) / Book-let tray (small) (for DF-75) / Two positions (book-let) 2 - 4 sheets (for DF-75) / Two positions (book-let) 5 - 7 sheets (for DF-75)
  • Page 39 FS-9120DN/9520DN Service items Description Printing a status page for event log >>Print Description Event Log Prints the status page of event logs. Purpose To see the characteristics of each printer and influences of environment. Method 1. Enter the service mode [>>Printing Event Log].
  • Page 40 Bit 0: always 0 Bit 1: 0: Overseas 1: Domestic (Japan) Bit 2: Not used Bit 3: Not used Bit 4: 0: Kyocera 1: OEM Bit 5: 0: For Europe 1: For U.S. Bit 6: 0 Non MICR mode 1: MICR mode...
  • Page 41 FS-9120DN/9520DN Service items Description Initializing the developer unit >>Developer Description Feeds toner from the toner container to the developer unit. Purpose To execute when the developer unit has been replaced. Method 1. Enter the service mode [>>Developer]. 2. Press the Enter key. "?" will be displayed.
  • Page 42 FS-9120DN/9520DN 1-4-2 Maintenance mode (1) Maintenance mode The printer is equipped with a maintenance function which can be used to maintain and service the machine. To run the maintenance mode, Insert a compact flash card to which the API program has been written into the printer and load the API program to the printer using either method.
  • Page 43 FS-9120DN/9520DN >Check Cover SW> Checking the printer cover switch See page 1-4-14. [U038]&InterLock Setting the amount of slack in the paper >Set of Paper > [U051] Loop See page 1-4-15. Performing fine adjustment of >Adjust Motor > the motor speed [U053] Speed See page 1-4-16.
  • Page 44 FS-9120DN/9520DN Setting the destination >Destination > feeder PF-75 [U252] See page 1-4-25. >Set LSU Type Setting LSU type See page 1-4-25. [U274] Setting the face-up unit >Face-Up Option> [U391] See page 1-4-26. Outputs of the history of events of >Print Menu >...
  • Page 45 FS-9120DN/9520DN (3) Contents of maintenance mode items Maintenance Description item No. U002 Initializing data for engine controller Description Initializing the backup RAM for engine controller to return to the original settings. Purpose Used to return the machine settings to initial settings.
  • Page 46 FS-9120DN/9520DN Maintenance Description item No. U031 Checking switches for paper conveying Description Displays the on-off status of each paper detection switch on the paper path. Purpose To check if the switches for paper conveying operate correctly. Method 1. Enter the maintenance mode and press the key to display "U031".
  • Page 47 FS-9120DN/9520DN Maintenance Description item No. U035 Setting folio size Description Sets the type of paper when using Folio or Oficioll. Purpose To prevent image loss that occurs depending on the difference of paper type. Method 1. Enter the maintenance mode and press the key to display "U035".
  • Page 48 FS-9120DN/9520DN Maintenance Description item No. U051 Setting the amount of slack in the paper Description Changes the preset value of the amount of slack of resist or feed. Purpose To adjust when the leading edge of the image is not printed or fluctuates irregularly or paper is bent in Z shape.
  • Page 49 FS-9120DN/9520DN Maintenance Description item No. U053 Performing fine adjustment of the motor speed Description Performs fine adjustment of the speeds of the motors. Purpose Used to adjust the speed of the respective motors when the magnification is not correct. Method 1.
  • Page 50 FS-9120DN/9520DN Maintenance Description item No. U101 Setting control voltages Description Changes the developing bias voltage and transfer voltage by changing the developing bias control voltage and transfer control voltage. Purpose To check or change the developing bias and transfer voltage.
  • Page 51 50 to 150 (sec) BIAS TIME Developing bias on time 500 to 1000 (msec) 700/540* *: FS-9120DN/9520DN 4. Press the ENTER key. "_" will blink. >>ON TIME [112.1] ### sec. 5. Press the key to move "_" to the digit position at which the value is to be changed and press the key to change the preset value.
  • Page 52 FS-9120DN/9520DN Maintenance Description item No. U114 Temperature setting/humidity setting 1. Press the ENTER key. "_" will blink. >>Temp [114.2] ### 2. Press the key to move "_" to the digit position at which the value is to be changed and press the key to change the preset value.
  • Page 53 FS-9120DN/9520DN Maintenance Description item No. U144 Setting toner loading operation Description Sets toner loading operation after completion of printing. Purpose To set whether or not toner is loaded on the drum after low density printing. Normally no change is necessary from the initial setting.
  • Page 54 MH OFF UP OFF time of fixing heater M -10 to +10 (°C) *: FS-9120DN/9520DN The respective temperatures are to be set such that 2ND TEMP > = 1ST TEMP. 4. Press the ENTER key. "_" will blink. >>CONTROL TEMP [161.1]...
  • Page 55 FS-9120DN/9520DN Maintenance Description item No. U196 Turning the fixing heater on Description Turns the fixing heater M or S on. Purpose To check fixing heaters turning on. Method 1. Enter the maintenance mode and press the key to display "U196".
  • Page 56 FS-9120DN/9520DN Maintenance Description item No. U199 Checking the fixing temperature Description Displays the fixing temperature, the ambient temperature and the absolute humidity. Purpose To check the fixing temperature, the ambient temperature and the absolute humidity. Method 1. Enter the maintenance mode and press the key to display "U199".
  • Page 57 FS-9120DN/9520DN Maintenance Description item No. U237 Setting finisher stack quantity Description Sets the number of sheets of stack on the intermediate tray in the optional finisher. Purpose To change the setting when a stack malfunction has occurred. Method 1. Enter the maintenance mode and press the key to display "U237".
  • Page 58 0 to 2 LSU Power LSU output power Low or High Low/High* *: FS-9120DN/9520DN 4. Press the ENTER key. 5. Press the key to change the preset value. 6. Press the ENTER key. The value is set. To keep the preset value, press the CANCEL key.
  • Page 59 FS-9120DN/9520DN Maintenance Description item No. U391 Setting the face-up unit Description Sets whether or not to perform face-up output through the optional face-up unit. Purpose To set this mode for special users who install only the face-up unit to perform face-up output. For users who use both the finisher and the face-up unit, do not set this mode.
  • Page 60 FS-9120DN/9520DN Maintenance Description item No. U393 Initializing data for FRPO Description Initializes each preset value of FRPO. Purpose To reset each preset value of FRPO to the initial values. Method 1. Enter the maintenance mode and press the key to display "U393".
  • Page 61 FS-9120DN/9520DN Maintenance Description item No. U395 Checking the size in MP tray Description Displays the size of paper set in the MP tray. Purpose To check to see if the size switch of the MP tray operates correctly. Method 1. Enter the maintenance mode and press the key to display "U395".
  • Page 62 FS-9120DN/9520DN Maintenance Description item No. U398 Adjusting left margin of image printing for each paper cassette Description Adjusts the left margin of image printing for each paper cassette. Purpose To adjust the left margin if it is displaced depending on the paper cassette. Before adjusting this item, use U402 to adjust the left margin of the upper cassette of the printer.
  • Page 63 FS-9120DN/9520DN Maintenance Description item No. U402 Adjusting margins of image printing Description Adjusts the margins of image printing for feeding from the upper cassette of the printer. Purpose Used if margins are not correct. Method 1. Enter the maintenance mode and press the key to display "U402".
  • Page 64 FS-9120DN/9520DN Maintenance Description item No. U951 Checking connection status of each optional equipment Description Displays the connection status of each optional equipment. Purpose To check the connection status of each optional equipment. Method 1. Enter the maintenance mode and press the key to display "U951".
  • Page 65 FS-9120DN/9520DN 1-4-3 Maintenance (1) Replacing the toner container Assuming an average toner coverage of 5% and Ecoprint mode turned off, the toner container will need replacing approximately once every 40,000 pages.* * For a new printer with a toner kit installed for the first time, the number of copies that can be printed will be approximately 20,000.
  • Page 66 FS-9120DN/9520DN 4. Seal up the old toner container with the supplied plastic bag and dispose it. Plastic bag Old toner container Figure 1-4-5 5. Take out the new toner container from the Toner container bag, and then lightly tap it on the top 5 to 6 times.
  • Page 67 FS-9120DN/9520DN 7. Grasp the handle on the toner container and insert the toner container along the rail of the Toner container printer. Figure 1-4-8 8. Hold the toner container by hands and fully insert it into the printer. Figure 1-4-9 9.
  • Page 68 FS-9120DN/9520DN 10. Remove the seal from the rear of the old waste toner box, and then close the opening of the box with the seal. Seal up the old waste toner box with the supplied plastic bag and dispose it.
  • Page 69 FS-9120DN/9520DN 13. Attach the grid cleaner to the printer aligning with the notches. Grid cleaner Figure 1-4-14 14. Gently pull the main charger unit as far as it will go, push and pull it several times, and then push it back in.
  • Page 70 FS-9120DN/9520DN 16. Remove the blue colored cleaning brush. Cleaning brush Figure 1-4-17 17. Pull up the conveying cover lock lever on the Conveying cover left side of the printer, and open the conveying cover. Conveying cover lock lever Figure 1-4-18 18.

  • Page 71: Paper Misfeed Detection

    FS-9120DN/9520DN 1-5-1 Paper misfeed detection (1) Paper misfeed indication When a paper misfeed occurs, the printer immediately stops printing and displays the jam location on the operation panel. To remove paper jammed in the printer, open the front cover, conveying cover, side cover or cassette.
  • Page 72 FS-9120DN/9520DN Section Jam code Description Conditions Paper feed No paper feed from the Feed switch 1 (FSW1) does not turn on within a specified section upper cassette time of the upper paper feed clutch (PFCL-U) turning on; the clutch is then successively turned off for 1 s and turned back on, but the switch again fails to turn on within a specified time.
  • Page 73 FS-9120DN/9520DN Section Jam code Description Conditions Paper feed Multiple sheets in paper Feed switch 1 (FSW1) does not turn off within a specified section feed section time of feed switch 1 (FSW1) turning on. Feed switch 2 (FSW2) does not turn off within a specified time of feed switch 2 (FSW2) turning on.
  • Page 74 FS-9120DN/9520DN Section Jam code Description Conditions Fixing sec- Misfeed in fixing section The eject switch (ESW) does not turn on within a specified tion (upper cassette) time of the registration clutch (RCL) turning on. The feedshift switch (FSSW) does not turn on within a speci- fied time of the registration clutch (RCL) turning on.
  • Page 75 FS-9120DN/9520DN Section Jam code Description Conditions Duplex Duplex paper conveying The duplex paper conveying switch (DUPPCSW) does not section section 1 turn on within a specified time of the feedshift switch (FSSW) turning on. The duplex paper conveying switch (DUPPCSW) does not turn off within a specified time of the feedshift switch (FSSW) turning off.
  • Page 76 FS-9120DN/9520DN (3) Paper misfeeds Problem Causes/check procedures Corrective measures A piece of paper torn from Check visually and remove it, if any. A paper jam in the print paper is caught paper feed, convey- around feed switch 1/2/3, ing or eject section...
  • Page 77 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures Electrical problem with the Check (see page 1-5-37). A paper jam in the lower paper feed clutch. paper feed section is indicated during printing (no paper feed from lower cas- sette). Jam code 11 Paper in the paper feeder Change the paper.
  • Page 78 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures Paper in the paper feeder Change the paper. A paper jam in the PF-70 lower cassette is paper feed section extremely curled. is indicated during Check if the paper feed Check visually and replace any deformed pulleys.
  • Page 79 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures Paper in the paper feeder Change the paper. A paper jam in the PF-75 is extremely curled. paper feed section Check if the paper side Check visually and replace. is indicated during guides are deformed.
  • Page 80 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures (11) Broken feed switch 1 ac- Check visually and replace the switch if its actuator is broken. A paper jam in the tuator, feed switch 2 ac- paper feed section tuator or feed switch 3 ac- is indicated during t u a t o r .
  • Page 81 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures (14) Check if the upper paper Run maintenance item U032 and select the upper paper feed A paper jam in the feed clutch malfunctions. clutch on the operation panel to be turned on and off. Check the paper feed section status and remedy if necessary.
  • Page 82 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures (17) Electrical problem with the Check (see page 1-5-38). A paper jam in the registration clutch. paper conveying section is indicated during printing (Sec- ondary paper feed does not start). Jam code 05 (18) Broken feed switch 1 ac- Check visually and replace the switch if its actuator is broken.
  • Page 83 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures (21) Check if the feedshift sole- Run maintenance item U033 and select the feedshift solenoid on A paper jam in the noid malfunctions. the operation panel to be turned on and off. Check the status feedshift section is and remedy if necessary.
  • Page 84 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures (24) Broken duplex paper con- Check visually and replace the switch if its actuator is broken. A paper jam in the veying switch actuator or duplex section is feed switch 1 actuator. indicated during...
  • Page 85 FS-9120DN/9520DN 1-5-2 Self-diagnosis (1) Self-diagnostic function This printer is equipped with a self-diagnostic function. When a problem is detected, printing is disabled. The problem is displayed as a code consisting of digits number followed by a number between 0100 and F080, indicating the nature of the problem.
  • Page 86 FS-9120DN/9520DN (2) Self diagnostic codes Remarks Code Contents Causes Check procedures/corrective measures 0100 Backup memory device problem Defective Replace EEPROM. • Reading from or writing to the backup EEPROM. memory cannot be performed. 0110 Backup memory data problem Data damage of Contact the Service Administrative Divi- •...
  • Page 87 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 1010 Upper lift motor problem Defective upper Check if YC13-B9 on the engine controller • When the upper cassette is inserted, lift limit switch. PWB goes low when the upper lift limit the upper lift limit switch does not turn switch is turned off.
  • Page 88 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 1040 Desk lower lift motor problem Broken gears of Replace the desk lower lift motor. • When the lower cassette of the paper couplings of the feeder PF-70* is inserted, the desk...
  • Page 89 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 1120 Deck right lift of the paper feeder PF- The deck right lift Check the gears and belts, and remedy if 75* position problem does not rise necessary. • Deck level switch 2 does not turn on properly.
  • Page 90 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 2600 Deck conveying motor of the paper Defective deck Replace the deck conveying motor board/ feeder PF-75*/desk drive motor of conveying motor desk drive motor board and check for cor- the paper feeder PF-75* problem board/desk drive rect operation.
  • Page 91 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 4200 BD steady-state problem Defective laser Replace the LSU (see page 1-6-11). • While the polygon motor is on, a BD diode. error is detected three times continu- Defective polygon Replace the LSU (see page 1-6-11).
  • Page 92 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 6050 Abnormally low fuser unit thermistor Broken fuser Check for continuity. If none, replace the temperature heater M or S fuser heater M or S (see page 1-6-20). • When only fuser heater M is on, fuser wire.
  • Page 93 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 7400 Developing unit connector insertion Developing unit Reinsert the developing unit connector if problem connector in- necessary. • Absence of the developing unit is de- serted incorrectly. tected. Defective devel- Replace the developing unit.
  • Page 94 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 8030 Finisher* paper conveying belt prob- The paper con- Adjust the paper conveying belt so that it is veying belt is out in phase and check for correct operation. • An on-to-off or off-to-on state change of phase.
  • Page 95 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 8180 Finisher* rear side registration motor The rear side reg- Reinsert the connector. Also check for con- problem istration motor tinuity within the connector cable. If none, • If the rear side registration home posi- connector makes remedy or replace the cable.
  • Page 96 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 8320 Booklet stitcher* rear jog motor A problem is de- See the booklet stitcher service manual. problem tected with the rear jog motor. 8340 Booklet stitcher* staple motor prob- A problem is de- See the booklet stitcher service manual.
  • Page 97 FS-9120DN/9520DN Remarks Code Contents Causes Check procedures/corrective measures 8480 Booklet stitcher* broken punch A broken punch See the booklet stitcher service manual. power source wire problem power source wire problem is de- tected. Main controller PWB error Defective main Replace the main controller PWB. See •...

  • Page 98: Image Formation Problems

    FS-9120DN/9520DN 1-5-3 Image formation problems (1) No image appears (2) No image appears (3) Image is too light. (4) Background is visible. (entirely white). (entirely black). See page 1-5-29 See page 1-5-29 See page 1-5-30 See page 1-5-30 (8) One side of the print...
  • Page 99 FS-9120DN/9520DN (1) No image appears Causes (entirely white). 1. No transfer charging. 2. No laser beam output. 3. No developing bias is output. Causes Check procedures/corrective measures 1. No transfer charging. Reinsert the connector. Also check for continuity within the A.
  • Page 100 FS-9120DN/9520DN (3) Image is too Causes light. 1. Insufficient toner. 2. Deteriorated toner. 3. The transfer voltage is not output properly. 4. Dirty main charger wire. 5. EcoPrint mode enabled. Causes Check procedures/corrective measures 1. Insufficient toner. If the display shows the message requesting toner replenishment, replace the cartridge.
  • Page 101 FS-9120DN/9520DN (6) A black line appears Causes longitudinally. 1. Dirty or flawed drum. 2. Deformed or worn cleaning blade. 3. Dirty main charger wire. Causes Check procedures/corrective measures 1. Dirty or flawed drum. Perform the drum refresh operation. If the drum is flawed, replace the drum unit.
  • Page 102 FS-9120DN/9520DN (9) Black dots appear on Causes the image. 1. Dirty or flawed drum. 2. Deformed or worn cleaning blade. 3. Dirty drum separation claws. 4. Dirty heat roller separation claws. Causes Check procedures/corrective measures 1. Dirty or flawed drum.
  • Page 103 FS-9120DN/9520DN (12) Paper creases. Causes 1. Paper curled. 2. Paper damp. 3. Defective pressure springs. 4. Defective separation. 5. Defective fans. Causes Check procedures/corrective measures 1. Paper curled. Check the paper storage conditions. 2. Paper damp. Check the paper storage conditions.
  • Page 104 FS-9120DN/9520DN (15) Fusing is poor. Causes 1. Wrong type of paper. 2. Defective pressure springs. 3. Flawed press roller. 4. Defective fuser heater S. Causes Check procedures/corrective measures 1. Wrong paper. Check if the paper meets specifications. Replace paper. 2. Defective pressure springs.

  • Page 105: Electrical Problems

    FS-9120DN/9520DN 1-5-4 Electrical problems Problem Causes Check procedures/corrective measures No electricity at the power Measure the input voltage. The machine does outlet. not operate when The power cord is not Check the contact between the power plug and the outlet.
  • Page 106 FS-9120DN/9520DN Problem Causes Check procedures/corrective measures Defective eject switch. Run maintenance item U031 and turn the eject switch on and off The eject motor manually. If "1" is not displayed when the switch is on or "0" is does not operate.
  • Page 107 FS-9120DN/9520DN Problem Causes Check procedures/corrective measures (12) Broken cooling fan motor 6 Check for continuity across the coil. If none, replace cooling fan Cooling fan motor 6 coil. motor 6. does not operate. Poor contact in the cooling Reinsert the connector. Also check for continuity within the con- fan motor 6 connector ter- nector cable.
  • Page 108 FS-9120DN/9520DN Problem Causes Check procedures/corrective measures (19) Broken MP paper feed Check for continuity across the coil. If none, replace the MP pa- The MP paper feed clutch coil. per feed clutch. clutch does not op- Poor contact in the MP Reinsert the connector.
  • Page 109 FS-9120DN/9520DN Problem Causes Check procedures/corrective measures (25) Broken wire in fuser heater Check for continuity across each heater. If none, replace the The fuser heater M or S. heater M or S. does not turn on Fuser unit thermostat trig- Check for continuity across thermostat.
  • Page 110 FS-9120DN/9520DN Problem Causes Check procedures/corrective measures (32) Poor contact in the MP Reinsert the connector. Also check for continuity within the con- The message re- paper switch connector nector cable. If none, remedy or replace the cable. questing paper to be terminals.
  • Page 111 FS-9120DN/9520DN Problem Causes Check procedures/corrective measures (36) A piece of paper torn from Check and remove if any. A paper jam in the print paper is caught paper feed, paper around feed switch 1/2/3, conveying or fuser registration switch, section is indicated...

  • Page 112: Mechanical Problems

    FS-9120DN/9520DN 1-5-5 Mechanical problems Problem Causes/check procedures Corrective measures Check if the surfaces of the following rollers Clean with isopropyl alcohol. No primary paper feed. or pulleys are dirty with paper powder: up- per/lower forwarding pulleys, upper/lower paper feed pulleys, upper/lower separation...
  • Page 113 FS-9120DN/9520DN Problem Causes/check procedures Corrective measures Check if the pulleys, rollers and gears oper- Grease the bearings and gears. Abnormal noise is ate smoothly. heard. Check if the following electromagnetic Correct. clutches are installed correctly: upper/lower paper feed clutches, feed clutches 1/2/3, MP paper feed clutch and MP feed clutch.

  • Page 114: Precautions For Assembly And Disassembly

    FS-9120DN/9520DN 1-6-1 Precautions for assembly and disassembly (1) Precautions • When handling PWBs (printed wiring boards), do not touch connectors with bare hands. It will damage the PWB. • Do not touch any PWB containing ICs with bare hands or any object prone to static charge.

  • Page 115: Paper Feed Section

    FS-9120DN/9520DN 1-6-2 Paper feed section (1) Detaching and refitting the forwarding, paper feed and separation pulleys Follow the procedure below to replace the forwarding, paper feed and separation pulleys. Procedure • Removing the primary paper feed units 1. Open the front cover and pull out the upper and lower cassettes.
  • Page 116 FS-9120DN/9520DN • Removing the paper feed pulley Paper feed shaft 6. Remove the two stop rings. Stop rings 7. Pull the paper feed shaft toward the rear of the primary paper feed unit (in the direction of the arrow) and remove the paper feed pulley.
  • Page 117 FS-9120DN/9520DN (2) Detaching and refitting the MP separation, MP paper feed and MP forwarding pulleys Follow the procedure below to replace the MP separation, MP paper feed and MP forwarding pulleys. Procedure • Removing the MP tray unit 1. Remove the four screws holding the lower right cover and then the cover.
  • Page 118 FS-9120DN/9520DN 4. Raise the MP separation shaft as shown in the diagram, remove the holder plate and the bushing, and then remove the MP separation Holder plate pulley. * Take care not to remove the spring pin of the Bushing gear at the rear of the MP separation shaft.
  • Page 119 FS-9120DN/9520DN 8. Raise the MP paper feed shaft as shown in Stop ring the illustration, remove the stop ring, and then remove the MP paper feed pulley. MP paper feed shaft Caution: • When fitting the MP paper feed pulley, keep the blue end of the paper feed toward the machine rear.
  • Page 120 FS-9120DN/9520DN 12. Remove the stop ring of the MP paper feed Stop ring Bushing shaft and slide the bushing in the direction of the arrow. MP paper feed shaft Figure 1-6-16 13. Slide the MP forwarding pulley shaft MP forwarding pulley shaft temporarily toward the rear side and then raise it to remove from the MP tray unit.
  • Page 121 FS-9120DN/9520DN 15. Remove the stop ring and slide the MP forwarding pulley with the forwarding pulley Stop ring retainer from the shaft to remove it. 16. Replace the MP separation, MP paper feed and MP forwarding pulleys. MP forwarding pulley...
  • Page 122 FS-9120DN/9520DN (3) Detaching and refitting the left and right registration cleaner Follow the procedure below to replace the left or right registration cleaner. Procedure • Left registration cleaner Film 1. Open the conveying cover and remove the Left ragistration roller transfer roller assembly (see page 1-6-17).
  • Page 123 FS-9120DN/9520DN • Right registration cleaner 1. Remove the developing unit and drum unit (see pages 1-6-14 and 16). 2. Remove the right registration cleaner. 3. Replace the right registration cleaner and refit all the removed parts. * To install the right registration cleaner, install it holding the frame of the registration guide between the cleaner.

  • Page 124: Laser Scanner Unit

    FS-9120DN/9520DN 1-6-3 Laser scanner unit (1) Detaching and refitting the laser scanner unit Take the following procedure when the laser scanner unit is to be checked or replaced. Procedure 1. Remove the developing unit and drum unit (see pages 1-6-14 and 16).
  • Page 125 FS-9120DN/9520DN 5. Remove the two screws and detach the connector and then remove the fan duct. Fan duct Connector Figure 1-6-27 6. Remove the six screws holding the toner Toner container retainer container retainer and then the retainer. Figure 1-6-28 7.
  • Page 126 FS-9120DN/9520DN (2) Adjusting the skew of the laser scanner unit (reference) Perform the following adjustment if the leading and trailing edges of the print image are laterally skewed (lateral squareness not obtained). Since this adjustment uses the test page that is output from the maintenance mode, prepare the compact flash card to which the maintenance mode has been written and load the maintenance mode to the printer to carry out this adjustment (See page 1-4-9).

  • Page 127: Drum Section

    FS-9120DN/9520DN 1-6-4 Drum section (1) Detaching and refitting the drum unit Follow the procedure below to replace the drum unit. Cautions: • Avoid direct sunlight or strong light when detaching and refitting the drum unit. • Never touch the drum surface when holding the drum unit.
  • Page 128 FS-9120DN/9520DN (3) Detaching and refitting the drum separation claw assemblies Follow the procedure below to replace the drum separation claw assemblies. Procedure 1. Remove the drum unit (see page 1-6-14). Drum separation claw assemblies 2. Push the drum separation claw assemblies with the minus driver from the top of the corner hole and remove the claw assemblies.
  • Page 129 FS-9120DN/9520DN 1-6-5 Developing section (1) Detaching and refitting the developing unit Follow the procedure below to replace the developing unit. Procedure 1. Open the front cover. 2. Remove the toner container and waste toner box. 3. Remove the screw and turn the developing release lever in the direction of the arrow.

  • Page 130: Transfer Section

    FS-9120DN/9520DN 1-6-6 Transfer section (1) Detaching and refitting the transfer roller assembly Follow the procedure below to replace the transfer roller assembly. Procedure 1. Open the conveying cover. 2. While holding down the projection, slide the Transfer roller assembly transfer roller assembly toward the front to remove it.
  • Page 131 FS-9120DN/9520DN 1-6-7 Fuser section (1) Detaching and refitting the fuser unit Follow the procedure below to check or replace the fuser unit. Procedure 1. Open the front cover and conveying cover. 2. Remove the two screws holding the front left cover and then the cover.
  • Page 132 FS-9120DN/9520DN 3. Remove the heat roller separation claws from the upper fuser cover. 4. Replace the heat roller separation claws and refit all the removed parts. Heat roller separation claws Figure 1-6-38 (3) Detaching and refitting the press roller Follow the procedure below to replace the press roller.
  • Page 133 FS-9120DN/9520DN (4) Detaching and refitting the fuser heater M and S Follow the procedure below to replace the fixing heater M and S. Procedure 1. Remove the fuser unit (see page 1-6-18). 2. Remove the upper fuser cover (see page 1-6- 18).
  • Page 134 FS-9120DN/9520DN (5) Detaching and refitting the heat roller Follow the procedure below to replace the heat roller. Procedure 1. Remove the fuser unit (see page 1-6-18). Fuser gear 2. Remove the upper fuser cover (see page 1-6- 18). 3. Remove the press roller and fuser heater M and S (see pages 1-6-20).
  • Page 135 FS-9120DN/9520DN (6) Detaching and refitting the fuser unit thermistor 1 and 2 Follow the procedure below to replace the fuser unit thermistor 1 and 2. Procedure 1. Remove the fuser unit (see page 1-6-18). 2. Remove the upper fuser cover (see page 1-6- 18).
  • Page 136 FS-9120DN/9520DN 1-6-8 PWBs (1) Detaching and refitting the main controller PWB Follow the procedure below to detaching and refitting the main controller PWB. Procedure 1. Remove the two screws. 2. Draw the main controller PWB. Main controller PWB Figure 1-6-49...
  • Page 137 FS-9120DN/9520DN (2) Detaching and refitting the engine controller PWB Follow the procedure below to detaching and refitting the engine controller PWB. Procedure Rear cover 1. Remove the eight screws and then remove the rear cover. Figure 1-6-50 Controller-box cover 2. Remove the thirteen screws and then remove the controller-box cover.
  • Page 138 FS-9120DN/9520DN (3) Detaching and refitting the power supply unit Follow the procedure below to detaching and refitting the power supply unit. Procedure 1. Remove the eight screws and then remove the rear cover (see page 1-6-24). 2. Remove the thirteen screws and then remove Connector the controller-box cover (see page 1-6-24).
  • Page 139 FS-9120DN/9520DN (4) Detaching and refitting the high-voltage transformer unit Follow the procedure below to detaching and refitting the high-voltage transformer unit. Procedure 1. Remove the eight screws and then remove the rear cover (see page 1-6-24). 2. Remove the thirteen screws and then remove the controller-box cover (see page 1-6-24).
  • Page 140 FS-9120DN/9520DN (5) Detaching and refitting the operator panel PWB Follow the procedure below to detaching and refitting the operator panel PWB. Procedure 1. Insert a flat-blade screwdriver or the like into the clearance and remove the operation Operator panel cover panel cover.
  • Page 141 System firmware file name example B10K15000.bcmp compression Boot program is included. Version code: Version 150.00 ID code for Kyocera Machine code: FS-9120DN (B19) FS-9520DN (B10) Engine firmware file name example EB10K0012.x Void Version code: Version 0012 ID code for Kyocera...
  • Page 142 FS-9120DN/9520DN (2) Downloading firmware via the parallel interface To download the system or engine firmware using the parallel interface, use the procedure below. Note that you can download both the system and engine firmware at a time. Connecting the parallel printer cable 1.
  • Page 143 FS-9120DN/9520DN (3) Downloading firmware using the memory card The procedure below provides how to download firmware from a memory card. A memory card can hold both the system and the engine firmware together for downloading these firmware at a time.
  • Page 144 FS-9120DN/9520DN Downloading firmware file Memory card 1. Confirm that the printer's power switch is set to off. 2. Insert the memory card into the printer's memory card slot. Memory card slot Figure 1-7-6 3. Turn printer power on. The firmware file in...
  • Page 145 FS-9120DN/9520DN (4) Downloading message data To download the new message data for the display, proceed as follows: Connecting the parallel printer cable 1. Turn printer and PC power off. 2. Connect the parallel printer cable between the PC and the printer.
  • Page 146 FS-9120DN/9520DN 2-1-1 Paper feed section The paper feed section consists of the primary feed and secondary feed subsections. Primary feed conveys paper from the upper cassette, lower cassette or MP tray to the left and right registration rollers, at which point secondary feed takes place and the paper travels to the transfer section in sync with the printing timing.
  • Page 147 FS-9120DN/9520DN The MP tray can be hold up to 200 sheets of paper at one time. Paper is fed from the MP tray by the rotation of the MP forwarding pulley and MP paper feed pulley. Also during paper feed, the MP separation pulley prevents multiple sheets from being fed at one time by the torque limiter.
  • Page 148 FS-9120DN/9520DN EPWB YC16-B6 YC10-A2 FCL1 FCL1 YC11-14 FSW1 YC11-17 FSW1 LICSW-U PSW-U LICSW-U YC13-B9 PSW-U PFCL-U YC13-B12 PFCL-U YC16-B1 FCL2 YC13-A12 FCL2 LICSW-L PSW-L LICSW-L YC13-B15 FSW2 PSW-L PFCL-L YC13-B18 PFCL-L YC16-B4 FCL3 FCL3 YC13-A5 FSW3 FSW3 YC13-A2 FSW2 YC13-A7...
  • Page 149 At the same time, feed clutch 1 (FCL1) turns on for 30 ms. e: 124/96 ms (FS-9120DN/9520DN) after the trailing edge of the paper turns the registration switch (RSW) off, the registration clutch (RCL) turns off.

  • Page 150: Main Charging Section

    FS-9120DN/9520DN 2-1-2 Main charging section The main charging section consists of the main charger assembly, drum and so on. The drum is electrically charged uniformly by means of a grid to form a latent image on the surface. The main charger unit charges the drum so that a latent image is formed on the surface, the shield grid ensuring the charge is applied uniformly.
  • Page 151 The leading edge of the paper turns on the eject switch (ESW), and at the same time the eject motor (EM) turns on. d: 309/239 ms (FS-9120DN/9520DN) after the paper is ejected and the eject switch (ESW) turns off, main charging (MC REM) ends.
  • Page 152 FS-9120DN/9520DN 2-1-3 Laser scanner unit (1) Laser scanner unit Print data formed with the controller is processed as image data and sent to the laser scanner unit (LSU). By repeatedly turning the laser on and off, the laser scanner unit forms a latent image on the drum surface.
  • Page 153 2 Collimator lens: Collimates the diffused laser beam emitted from the laser diode to convert it into a cylindrical beam. 3 Cylindrical lens: Shapes the collimated laser beam to suit the printing resolution. 4 Polygon mirror: Nine-facet mirror that rotates at approximately 28031/36220 (FS-9120DN/9520DN) rpm with each face reflecting the laser beam toward the drum for one main-direction scan.
  • Page 154 FS-9120DN/9520DN The dimensions of the laser beam are as shown in Figure 2-1-9. Less than 100 µm Less than 85 µm Figure 2-1-9 Scanning in the main direction is provided by the rotating polygon mirror, while scanning in the auxiliary direction is provided by the rotating drum, forming a static latent image on the drum.
  • Page 155 FS-9120DN/9520DN 2-1-4 Developing section The developing section consists of the developing unit and the toner container. The developing unit consists of the developing roller where a magnetic brush is formed, the doctor blade and the developing spirals that agitate the toner.
  • Page 156 FS-9120DN/9520DN (1) Formation of magnetic brush The developing roller consists of a magnet roller with four poles and a sleeve roller. Rotation of the sleeve roller around the magnet roller entrains toner, which in turn forms a magnetic brush at pole N1 on the magnet roller. The height of the magnetic brush is regulated by the doctor blade;...
  • Page 157 FS-9120DN/9520DN (2) Computing the absolute humidity The humidity sensor (HUMSENS) converts the relative humidity detected by the humidity sensing element into a voltage and sends it to the engine controller PWB (EPWB). The engine controller PWB (EPWB) computes the absolute humidity based on this HUMSENS signal and the temperature (ETTH signal) detected by the external temperature thermistor (ETTH).

  • Page 158: Transfer And Separation Sections

    FS-9120DN/9520DN 2-1-5 Transfer and separation sections The transfer and separation section consists mainly of the transfer roller, separation electrode and drum separation claws. A high voltage generated by the high-voltage transformer unit (HVTU) is applied to the transfer roller for transfer charging.
  • Page 159 154 to 255 ms after the registration clutch (RCL) turns on to start secondary paper feed, transfer charging (TC REM) and separation bias (SC REM) starts. b: 325/260 ms (FS-9120DN/9520DN) after the trailing edge of the paper turns the registration switch (RSW) off, transfer charging (TC REM) ends.

  • Page 160: Cleaning And Charge Erasing Sections

    FS-9120DN/9520DN 2-1-6 Cleaning and charge erasing sections The cleaning section consists of the cleaning blade that removes residual toner from the drum surface after the transfer process, and the cleaning spiral that carries the residual toner back to the waste toner box.
  • Page 161 FS-9120DN/9520DN 2-1-7 Fuser section The fuser section consists of the parts shown in Figure 2-1-20. When paper reaches the fuser section after the transfer process, it passes between the press roller and heat roller, which is heated by fuser heaters M or S (FH-M or FH-S).
  • Page 162 1 s after fuser heater M (FH-M) turns on, the polygon motor (PM) of the laser scanner unit turns on. d: When the fuser temperature reaches 115°C/239°F (FS-9120DN)/120°C/248°F (FS-9520DN), the printer enters primary stabilization, and fuser heater M (FH-M) turns off temporarily and turns on again after 8 s.

  • Page 163: Eject And Switchback Sections

    FS-9120DN/9520DN 2-1-8 Eject and switchback sections The eject and switchback sections eject paper on which fuser has ended with the eject roller that is rotated by forward rotation of the eject motor. In duplex printing, paper is turned over by reverse rotation of the eject motor.
  • Page 164 The leading edge of paper (reverse face) turns on the eject switch (ESW), and at the same time the eject motor (EM) turns off for 50 ms and then starts forward rotation. d: 309/239 ms (FS-9120DN/9520DN) after passing of the trailing edge of the paper turns off the eject switch (ESW), the eject motor (EM) turns off.

  • Page 165: Duplex Unit

    FS-9120DN/9520DN 2-1-9 Duplex unit The duplex unit consists of the components shown in Figure 2-1-24. In duplex mode, after printing on to the reverse face of the paper, the paper is reversed in the switchback section and conveyed to the duplex unit. The paper is then conveyed to the printer paper feed section by the upper and lower duplex feed rollers.
  • Page 166 FS-9120DN/9520DN (1) Paper conveying operation in duplex printing Paper of which printing onto the reverse side is complete is conveyed to the switchback section, the eject motor switches from normal rotation to reverse rotation to switch the eject roller to reverse rotation, and the paper conveying direction is reversed.

  • Page 167: Electrical Parts Layout 2

    FS-9120DN/9520DN 2-2-1 Electrical parts layout (1) PWBs Machine front Machine inside Machine rear Figure 2-2-1 PWBs 1. Main controller PWB (MPWB) ..... Implements firmware for managing data processing for printing, interface with PC and the network, etc. 2. Engine controller PWB (EPWB) ....Controls printer hardware including electrical components.

  • Page 168: Switches And Sensors 2

    FS-9120DN/9520DN (2) Switches and sensors Machine front Machine inside Machine rear Figure 2-2-2 Switches and sensors 1. Power switch (POWSW) ......Turns the AC power on and off. 2. Interlock switch (ILSW) ........ Turns the AC power for the fuser heater on and off.
  • Page 169 FS-9120DN/9520DN 20. Registration switch (RSW) ......Controls the secondary paper feed start timing. 21. Eject switch (ESW) ........Detects a paper misfeed in the fuser section. 22. Feedshift switch (FSSW) ......Detects a paper misfeed in the switchback section in a duplex print.

  • Page 170: Motor

    FS-9120DN/9520DN (3) Motors 10,11,12 Machine front Machine inside Machine rear Figure 2-2-3 Motors 1. Drive motor (DM) ......... Drives the machine. 2. Paper feed motor (PFM) ......Drives paper feed section. 3. Upper lift motor (LM-U) ........ Drives upper cassette lift.
  • Page 171 FS-9120DN/9520DN (4) Other electrical components 12 13 Machine front Machine inside Machine rear Figure 2-2-4 Other electrical components 1. Upper paper feed clutch (PFCL-U) ....Primary paper feed from the upper cassette. 2. Lower paper feed clutch (PFCL-L) ....Primary paper feed from the lower cassette.

  • Page 172: Power Supply Unit

    FS-9120DN/9520DN 2-3-1 Power supply unit Power supply unit Rectifier circuit D101 AC input 24 V DC D102 C101 24 V DC C102 output circuit 5 V DC Zero-cross circuit 5 V DC output C201 circuit Switching control circuit Fuser heater...
  • Page 173 FS-9120DN/9520DN 100V PC105 PC104 TR102 PC103 PC101 C208 IC205 PC102 C113 TR101 IC101 C205 Q102 Q205 L102 C109 C117 L209 C202 L210 C110 C203 C207 F203 C111 Q210 Q212 L205 T101 C214 D101 C228 C211 L207 L206 TH101 L101 Q216...
  • Page 174 FS-9120DN/9520DN Terminals (YC) Voltage Remarks TB-1 TB-2 120 V AC 120 V AC supply, input TB-1 TB-2 220-240 V AC 220-240 V AC supply, input TB-4 TB-5 120 V AC 120 V AC supply for POWSW, output TB-4 TB-5 220-240 V AC...
  • Page 175 FS-9120DN/9520DN 2-3-2 Engine controller PWB Engine controller PWB Address bus SRAM1 Data bus FLASH SRAM2 EEPROM EEPROM Printing data Engine G/A High-voltage transformer unit Main controller Detection signal input Reset Control signal output Paper feeder circuit Drum unit Developing unit...
  • Page 176 FS-9120DN/9520DN Figure 2-3-4 Engine controller PWB silk-screen diagram 2-3-5...
  • Page 177 FS-9120DN/9520DN Terminals (YC) Voltage Remarks 0/5 V DC SLEEP signal, output 0/5 V DC CFM4 remote signal, output 0/5 V DC (pulse) Zero-cross signal, input 5 V DC 5 V DC supply for PSU, output 0/5 V DC FH-M on/off, output...
  • Page 178 FS-9120DN/9520DN Terminals (YC) Voltage Remarks 0/5 V DC LSU VIDEO + signal, output 0/5 V DC LSU VIDEO - signal, output 0/5 V DC LSU PD signal, input 8-10 8-11 24 V DC 24 V DC supply for PM, output...
  • Page 179 FS-9120DN/9520DN Terminals (YC) Voltage Remarks 12-9 12-12 0/24 V DC PWSW-L paper width detection signal, input 12-10 12-12 0/24 V DC PWSW-L paper width detection signal, input 12-11 12-12 0/24 V DC PWSW-L paper width detection signal, input 13-A2 13-A1...
  • Page 180 FS-9120DN/9520DN Terminals (YC) Voltage Remarks 21-5 21-2 0 - 5 V DC OPPWB FPDAT signal, input 21-6 21-2 5 V DC 5 V DC supply for OPPWB, output 22-A1 22-A2 5/0 V DC (pulse) Main controller PWB PRINTN signal, output...
  • Page 181 FS-9120DN/9520DN 2-3-3 Main controller PWB LA [16:2] LA [16:2] LD [15:0] LD [15:0] PDATA [7:0] Front KUIO 2 KUIO 1 RS232C Parallel Ether EPWB Panel Driver IC Ether PHY LV245A (U21) (U22) (U23) (U25) TX_D [3:0] RX_D [3:0] Control Signals...
  • Page 182 FS-9120DN/9520DN U18 U17 U20 U19 YC10 Figure 2-3-6 Main controller PWB block diagram 2-3-11...
  • Page 183 FS-9120DN/9520DN Terminals (YC) Voltage Remarks 0/5 V DC (pulse) Compact flash D3 signal 0/5 V DC (pulse) Compact flash D4 signal 0/5 V DC (pulse) Compact flash D5 signal 0/5 V DC (pulse) Compact flash D6 signal 0/5 V DC (pulse)
  • Page 184 FS-9120DN/9520DN Terminals (YC) Voltage Remarks 3-16 0/5 V DC (pulse) Parallel I/F DATA8 signal 3-10 3-16 0/5 V DC (pulse) Parallel I/F ACK signal 3-11 3-16 0/5 V DC (pulse) Parallel I/F BUSY signal 3-12 3-16 0/5 V DC (pulse)
  • Page 185 FS-9120DN/9520DN 2-4-1...
  • Page 186 FS-9120DN/9520DN 2-4-2...
  • Page 187 FS-9120DN/9520DN 2-4-3...
  • Page 188 FS-9120DN/9520DN 2-4-4...
  • Page 189 FS-9120DN/9520DN 2-4-5...
  • Page 190 FS-9120DN/9520DN 2-4-6...
  • Page 191 FS-9120DN/9520DN Wiring diagram NFPCB INLET ILSW FUSER UNIT LIVE LIVE FH-M ON FH-S HEATER GROUND NEUTRAL FH-S ON CONTROLLER FH LIVE FH-M SSW1 NOISE FILTER MP tray FTH1 CFM4 MPPWSW SSW2 CFM4 REM MPFCL DH (OPTION) FROM F FTH2 (CN3)

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